System and method for cutting granite or similar materials

ABSTRACT

Improved methods including providing a frame saw system having multiple blades for cutting slabs of masonry materials. The improved methods allow for cutting masonry materials into slabs having surface small deviations. A process for cutting masonry blocks of granite, marble, rock, and the like, also includes positioning a support structure of a unifying material perpendicularly across the blade of the frame saw, wherein the support structure is adhered to at least one of the blades for keeping the blades in fixed relative positions, subjecting the block to a sawing operation using the frame saw, and at least substantially removing the support structure as the blades become submerged in the block.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional and claims the benefit of U.S. patentapplication Ser. No. 10/568,105 filed on Oct. 30, 2006, which is anational stage filing of International Patent Application No.PCT/US/04/26316, filed Aug. 13, 2004, which in turn claims priority toU.S. Provisional Patent Application No. 60/495,148, entitled “Method toImprove Tool Integrity When Cutting Stone,” filed Aug. 14, 2003.

BACKGROUND

This application relates to frame saw systems and methods ofmanufacturing slabs. In particular, this application relates to a methodand system for sawing a block of marble, granite, or similar rock bymeans of a multiple blade frame saw system.

Frames with multiple blades are commonly used for cutting or sawingblocks of a masonry material such as concrete, marble, granite,sandstone, limestone, fired brick or a like material, as well as forcutting blocks of composite material made of stone or marble chippingsbound together by a binder material. Such frames may have steel bladesor steel blades equipped with diamond-containing segments, with each ofthe blades being maintained under tension. Such tension may be supplied,for example, by one or more tension rods.

For example in U.S. Pat. No. 4,566,427, a device for cutting blocks ofgranite, marble, stone and similar materials is provided. Such a deviceincludes a plurality of sawing blades; a blade-carrying frame into whichat least two sawing blades are fixed and having slide means fordirecting horizontal motion of said frame; a drive motor unit connectedto said blade-carrying frame for displacing said sawing blade in areciprocating motion, a slide-carrying frame of generally rectangularcross-section, upright supports, a guide unit on each upright supportconnected to said slide-carrying frame for directing vertical movementof said slide-carrying frame, said slide means of said blade-carryingframe being adapted to fit within said slide-carrying frame, andvibration damping means for creating pressure on the top, bottom, andeach side of said slide means to urge said slide means away from contactwith said slide-carrying frame, thus providing a vibration dampenedconnection between said slide-carrying frame and said blade-carryingframe, whereby vibrations to the sawing blades is minimized.

In another example, in U.S. Pat. No. 5,233,968, a sawing machineincluding multiple blades in a stiff support framework is described tosaw stone blocks, and particularly granite. The sawing machine usesrectilinear travel wherein, in correspondence of the abrasion zone andin addition to the conventional translatory motion, a blade frame isused with a hammering or percussion movement of the saw blades onto thestone block being cut. The machine is designed so that the blades may“jump”, meaning that the blades may be lifted from the bottom of thecutting channels and then be dropped again therein in a short, rapidmovement.

In another granite sawing operation employing horizontal frame saws,each frame saw has up to 250 steel blades each more than 3 meters long,3-5 mm thick, and 50-200 mm tall. After sawing granite or marble blocksinto slabs, the slabs are polished to ultimately generate finishedcomponents such as tiles and blocks. Slabs may be considered to besufficiently flat if the surface deviates less than about 1.5 mm from aplane. Slabs of thickness variation of greater than about 2 mm cannot besorted and polished, and often must be scrapped. In another example, aslab's thickness variation may be considered acceptable for polishing ifthe difference between the thickest and thinnest points in the slabs isless than about 10% of the slab's nominal thickness.

To meet finished granite/marble product quality control requirementssuch as those detailed above, the blades must not deviate from asubstantially straight path as they cut through a block of marble orgranite. Blade deviation can arise when local forces cause the blade totwist, flex, or bend out of a plane, leading to cuts deviating from astraight path and slabs exceeding the allowable thickness variation.Additionally, blade deflection causes premature blade wear due to bladeflexing, buckling, and fracture.

One source of local forces causing blade flexing or deviation is theirregularities of the masonry material to be cut or sawed. Mined masonrymaterials typically have internal faults. Granite and marble materials,endowed with color and vein structure, are usually defective due tofracturing during geological formation. Some of the defects may beexternal, as caused by mining conditions with drill holes and otherasperities. As saw blades are used to cut as-mined masonry materials,the blades can experience highly variable forces due to theirregularities in the materials which may cause premature wear in steelblades and deviation from a substantially parallel cut in the slab. Asan additional problem in cutting or sawing masonry materials,superabrasive particles of the saw blades may be detached or pulled-outfrom superabrasive containing blades during operation. This pull-out ofthe superabrasive particles in the blades is heightened by theirregularities of the masonry material.

Because of the intrinsic defects in the raw masonry materials and theprior art cutting and sawing systems, the cutting of slabs from marbleand other rock is costly due to the large amount of reject materialand/or machine wear. There is a need for improved methods and systemsfor cutting slabs of masonry materials such as granite, marble, rock,and the like.

SUMMARY

An embodiment of the invention relates to a frame saw system, such as ahorizontal system having multiple parallel, spaced-apart blades, forcutting a block of granite, marble, or like material. In thisembodiment, the system includes a support structure of unifying materialbonded to at least one of the blades for keeping the blades in fixedrelative positions. In this embodiment, the support structure may forman integral cohesive mass and is removable from the frame saw system asthe blades are engaged in a swinging motion cutting into the block. Thesupport structure is removed and/or worn away as the blades engage theblock. The support material is completely removed when the blades arefully submerged in the block.

In another embodiment, the invention relates to a frame saw systemhaving multiple blades, wherein the individual blades are stabilizedwhen cutting or otherwise manufacturing slabs of masonry materials suchas granite, marble, rock, and the like. In this embodiment, the framesaw system may have one or more spacers located longitudinally inbetween individual saw blades for keeping the blades in fixed relativepositions. Out-of-plane blade deflection in a frame saw comprisingmultiple blades may be minimized in such a system by imposing sideforces on the blades, wherein the forces are applied to both sides ofthe frame saw and are directed perpendicularly to the individual blades.

In another embodiment, the frame saw systems are used in processes forcutting a block of granite, marble, or like material.

In another embodiment, the invention relates to a process for cutting ablock of granite, marble, or like material, wherein the surface of theblock is pretreated with a skim coat to substantially remove surfaceirregularities prior to cutting operations.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a block of granite, marble, or likestone which is about to undergo a sawing operation.

FIG. 1B is a cross sectional view of the block of granite, marble, orlike stone of FIG. 1A, with surface irregularities.

FIG. 2A is a side view of a horizontal saw frame system in the priorart.

FIG. 2B is a top view of a horizontal saw frame system in the prior art.

FIG. 2C is a top view of a horizontal saw frame system of one embodimentof the present invention.

FIG. 3A is a partial perspective view of an operation of an embodimentof the present invention, wherein a block of granite, marble, or likestone is about to undergo a sawing operation.

FIG. 3B is a cross sectional view of an embodiment of a sawingoperation, wherein a block of granite, marble, or like stone is about tocut by the multiple blade system of the invention.

FIG. 3C is a cross sectional view of one embodiment of the presentinvention, wherein a block of granite, marble, or like stone containingsurface irregularities is “treated” with a top skim coat.

FIG. 4 is a schematic view of one frame saw embodiment of the presentinvention showing compressive side forces applied to blades mounted in aswing-type frame saw.

FIG. 5 is a schematic top view of one frame saw embodiment of thepresent invention showing compressive side forces applied to bladesmounted in a swing-type frame saw.

DETAILED DESCRIPTION

Before the present structures and methods are described, it is to beunderstood that this invention is not limited to the particularprocesses, systems, compositions, or methodologies described, as thesemay vary. It is also to be understood that the terminology used in thedescription is for the purpose of describing the particular versions orembodiments only, and is not intended to limit the scope of the presentinvention which will be limited only by the appended claims.

It must also be noted that as used herein and in the appended claims,the singular forms “a”, “an”, and “the” include plural reference unlessthe context clearly dictates otherwise. Thus, for example, reference toa “blade” is a reference to one or more blades and equivalents thereofknown to those skilled in the art, and so forth. Unless definedotherwise, all technical and scientific terms used herein have the samemeanings as commonly understood by one of ordinary skill in the art.Although any methods and materials similar or equivalent to thosedescribed herein can be used in the practice or testing of embodimentsof the present invention, the preferred methods, devices, and materialsare now described. All publications mentioned herein are incorporated byreference in their entirety. Nothing herein is to be construed as anadmission that the invention is not entitled to antedate such disclosureby virtue of prior invention.

In the following description various embodiments of a frame saw systemand methods of cutting granite, marble, and other stone and masonrymaterials are provided.

In one embodiment of the invention, a simple and effective process tostabilize frame saw blades in cutting masonry blocks includes providingone or more unifying support structures perpendicularly across theindividual frame saw blades during cut initiation. In anotherembodiment, frame saw blade integrity may be maintained by applying askim coat to the surface of the masonry block prior to cutting. Inanother embodiment, a frame saw system comprising multiple individualblades with spacers located in between is provided. In anotherembodiment, compressive or clamping forces are applied to a collectionof adjacent blades mounted on a frame saw to increase their resistanceto deflection under the forces created by sawing.

Sawing Operations with Frame Saw: FIG. 1A is a schematic drawing of asawing operation, in which a representative masonry block 20 is cut intoslabs. The block 20 can be marble, granite, or like hard rock, and thelike, or a composite block made of chips or pieces of one or more stonematerials bound together by a binder.

FIG. 1B is a cross-section view of as-mined block 20, with the typicalsurface irregularities 21 including various high points, low points ordrill holes.

In a sawing operation of one embodiment of the invention, block 20 issubject to sawing in its longitudinal direction by means of a multipleblade frame of the horizontal kind, having saw blades 10 extendinghorizontally as illustrated in FIG. 1A. In one embodiment, the bladescomprise a cutting edge with superabrasive-containing segments mountedthereon to engage the block 20. Such superabrasive segments may includeparticles of diamond, cubic boron nitride or mixtures thereof. Inanother embodiment, the blades are made of steel and engage the block inconnection with a slurry comprising steel shot and lime dispersed inwater. The slurry may be poured over the frame saw system to aid incutting, wherein the steel shot fills the space between the granite andthe blades.

The blades 10 may be reciprocated along their length, as indicated bythe double-headed arrow “x,” in respective vertical cutting planes. Theblades 10 may be moved in the direction of the arrow “y” within thecutting zone relative to the block 20 by a feed mechanism (not shown),preferably with the pitch or distance between the blades beingapproximately the thickness of the finished slabs, for example, about 2cm. The cutting zone may be supplied with cooling water (not shown),which optionally may contain suspension siliceous sand, metal particlesor other abrasive particles. In some operations, the cooling water mayfurther include a surfactant to help increase the speed at which theblades penetrate the masonry materials, and it may reduce blade wear.The surfactants may be anionic or cationic materials such as alkylbenzyl sulfonate, alkyl sulfates derivatives of coconut oil and tallow,sodium dodecyl sulfate, alkyl ether sulfate, trimethyldodecyl ammoniumchloride, a polyalkylene oxide, and the like, or they may be othermaterials.

FIG. 2A is a schematic side view of a blade as mounted in a frame saw asused in related art. As shown in the figure, tensioning rods 16 atopposite ends of the blade may be attached to the blade via loading pins15, which may pass through holes in both the rod and the blade.Hydraulic pistons 11 built into one end of the frame 13 may createtension to keep blade 10 straight in operation.

FIG. 2B is a schematic top view of a conventional horizontal frame sawwherein a plurality of blades 10 are attached by tensioning rods 16 to aframe 13 to provide support to the blades. FIG. 2B shows a conventionalhorizontal frame saw where the middle section of blades 10 are withoutany unifying support system and are thus free to bow and twist under theforces of cutting.

Process to Stabilize Frame Saw Blades. In contrast to FIG. 2A and FIG.2B, FIG. 2C is a schematic top view of a horizontal frame operation ofone embodiment of the invention, wherein a unifying support system 40 isprovided across the blades. The unifying support system of the frame sawdepicted in FIG. 2C may be present at the initial stage of cutting theblock, during which time the cut paths of the blades are beingestablished as they engage the block 20 (not shown). Referring solely tothe x, y, and z reference frame in FIG. 1A, the unifying support systemmay be applied to any known frame saw across the blades in the “z”direction. Preferably, the support system is applied in the “z”direction across the middle section of the blades. As used herein, themiddle section refers to a location anywhere in the “middle” section ofthe blade in the “x direction”, an area representing about half of thetotal blade length, which is defined by the points at about ¼ bladelength from each of the two ends of the blade. One or more unifyingsupport systems 40 may be provided perpendicularly across the blades. Ifone unifying support system 40 is provided, it is preferably providedperpendicularly across the blades at about the mid-point between the twoends of the blades. The unifying support system 40 configuration mayvary.

If support 40 were a permanent fixture of the frame saw system, it wouldprovide support to the blades and hold the blades in a fixed position.However, a permanent fixture across the “z direction” of the bladeswould not allow the blades to cut the block any deeper than a fewinches. Such a permanent unifying support system would defeat thepurpose of a cutting operation by preventing cutting. Applicants havefound that a temporary support system that provides the blades withunifying support in the cut initiation step significantly reduces thepropensity for frame saw blades to twist, vibrate or bow, but stillallows the total thickness of the block to be cut by the blades. If oneblade experiences sufficient force to cause it to deform, the supportsystem that attaches the blade to adjacent blades will transfer the loadof the force across the other blades, thus reducing the stress on anysingle blade. Once the blades are fully engaged within the thickness ofthe block, the support system is not needed anymore. The support systemmay not be permanently attached to the blades and may therefore besubstantially removed or pulled away from the cutting surface as theframe saw becomes engaged in a block. In other embodiments, the supportsystem is “removed” in that it substantially erodes or wears away fromthe blades as the support material contacts the block as the bladesbecomes engaged in the block. Therefore, a support system may bedesigned so that it provides initial unifying support but issubstantially removed once the blades are engaged in the block so thatthe support does not interfere with the cutting operations.

One embodiment of supplying a unifying support system to a frame saw isdepicted in FIG. 3A. A process of stabilizing the frame saw assemblywith the temporary support 40 may include the steps of: (a) mixingpolymeric components such as a blended polyol water soluble mixture withan isocyanate fluid to form an expandable polymeric foam mixture whichis then injected under high pressure through the injection gun 30; and(b) dispersing the mixture from the gun across the plurality of bladesin the “z” direction. Once dispersed, the mixture may expand into foamwhich fills between the blades, forming a unifying cohesive massintegral with the blade system. The foam may be a one-component systemwith a polymeric blend such as a polymeric/polyol, polyurethaneprepolymer, polymeric hydrocarbon propellant to be delivered as a foamfrom a delivery device such as a tank or discharge nozzle. In anotherembodiment, the foam may include material such as polyurethane,polyethylene, e.g., Ethafoam® of Dow Chemical Company, polystyrene,and/or copolymers of the foregoing.

Polymeric foams are generally very adhesive by nature, and thus ensureadequate bonding to the blades to stabilize the blades in their place.They are also typically of sufficient density to remain in place betweenthe blades as they are applied, producing a spongy, three dimensional,compressible, elastomeric substance, with open or closed cells or porescontaining entrapped gas for energy absorption, providing a mechanismfor dampening vibration in the frame saw system in the cut initiationstep.

In another embodiment of the invention as illustrated in FIG. 3B, aunifying support system 40 is in the form of an interconnected system of“spacers,” prefabricated for the frame saw system with each width ofeach spacer being sized to fit in-between the saw blades to hold them inplace. Adhesive sprays are optionally put on the surface of the spacersand or the blades, thus providing bonding as a removable cohesive massbetween the support spacers and the blades.

As the cutting progresses beyond the initiation step to establish astraight cut (with the blades 10 being held in place by stabilizingsupport 40), the stabilizing support system may be removed in operationby being pulverized away by the block as the blades go deeper into theblock.

It should be noted that the several embodiments of the present inventionare not limited to polymeric materials in that various non-polymericmaterials capable of bonding to the blades for initial stabilization,and subsequently being worn or eroded away as blades 10 engage with themasonry block 20 in operation.

Illustrative non-foam materials, which may be polymers or non-polymers,suitable for use in the present invention may include cellulosic andpolymer materials such as polyurethane, polyvinyl, latex, polyurethane,acrylate, cellophane and other polymers, and cellulosics or compositesincluding but not limited to naturally found materials such as wood,mineral wools and cellulose products.

It should be further noted that the several embodiments of the presentinvention are not limited to the horizontal frame saw system asillustrated. The systems and processes the invention may be applied toany frame saw system known in the art wherein at least a pair of bladesare used, including but not limited to the systems disclosed in U.S.patent application Ser. No. 2003/0127086 and U.S. Pat. Nos. 3,662,734;4,566,427; and 5,233,965, each of which is incorporated herein byreference in its entirety.

Process to Further Stabilize Frame Saw System. In another embodiment ofthe invention to stabilize a frame saw system, in addition to or in lieuof providing a support system 40 to the frame saw operation, the framesawing operation is further stabilized by removing or reducing the localforces that cause the blades to twist, flex, or that cause the diamondsegments on the blades to be detached. In embodiments of the invention,the local forces may be minimized by simply replacing the surfaceirregularities inherent in the as-mined masonry blocks with a moreuniform and regular surface for a blade to engage, thus reducing thepeak forces on the blades.

As shown in FIG. 1B, the surface 21 of an as-mined block typically hasirregularities such as various high points, low points and/or drillholes. Applicants have found that the application of a skim coat 50 inFIG. 3C onto the surface surprisingly reduces or minimizes the stress onsteel blades in operation, allowing the blades to completely cut througha granite block without losing any, or substantially any, diamondsegments. Without the application of the skim coat, as many as 30% ofthe segments may be detached from the blades while the cutting operationbegins.

As used herein, “skim coat” 50 refers to a surface layer that adheres tothe surface 21 of the masonry block 20, of sufficient consistency andsmoothness to spread onto the surface of the block to level out theblock surface. In one embodiment of the invention, the skim coat is acomposition of about 1 part cement, e.g., Portland cement, to about 2parts sand, for a substantially smooth surface. Other compositions arepossible.

In another embodiment of the invention, a frame saw system comprises anumber of generally parallel, spaced apart blades wherein the blades aremounted onto the frame under tension to minimize out-of-planedeflections by imposing side forces on the blades. A front view of aframe saw system with side forces applied to the blade is depicted inFIG. 4. This frame saw may be used in connection with a unifying supportsystem and/or with a skim coat. Such a system may also be employed in aframe saw with steel blades used in connection with a slurry comprisingsteel shot and lime dispersed in water to engage the block. The slurrymay be poured over the frame saw system to aid in cutting, wherein thesteel shot fills the space between the granite and the blades.

Additionally, this saw system may be used with blades that have acutting edge with diamond-containing segments mounted thereon to engagethe block. Compressive or clamping forces are applied to a collection ofadjacent blades mounted on a frame saw to increase their resistance todeflection under the forces created by sawing. Such clamping forces maybe applied to the outer most blades in the frame saw and may be directedinwardly, toward each other, in the “z” direction. Any means by whichcompressive forces are applied to the blade set, as schematicallyillustrated in FIG. 4 are acceptable for improving control over bladedeflection.

In FIG. 4, the frame 13 comprises multiple blades 10 with spacers 60located longitudinally between the blades. The spacers are made of anysuitable material and are shaped so that they will fit between theblades of the frame saw. The spacers may be placed between theindividual blades for support and to minimize deflection. These spacersmay be a polymeric material, such as a polyurethane foam. These may bedesigned to retract while cutting as described in reference to theunifying support system design. Forces 70 are applied perpendicularlyand inwardly to the blades in order to minimize deflection.

An example of the frame saw system with compressive forces applied to acollection of adjacent blades is a steel framework mounted to the sawframe wherein the forces are applied across plates in contact with theoutermost blades, as illustrated in FIG. 5. As seen in FIG. 4, the framesaw system in FIG. 5 comprises multiple blades 10 with spacers 60located longitudinally between the blades. Compressive perpendicularforces may be applied by bolts 90 tightened against the plates 80through adjustable vertical mounts 100. The vertical mounts 100 may beheld using bolts 110 attached through horizontal guide ways 120 weldedto the saw frame 130.

The use of a slurry to aid in cutting and engaging the granite or othermaterial to be cut may be used in connection with any of the frame sawembodiments. The use of blades comprising superabrasive segments such asdiamond segments may be used in connection with any of the frame sawembodiments. The diamond segments may be attached to the blades in anyknown manner. For example, the diamond segments may be sinteredpolycrystalline diamond particles brazed to the blades. In the severalmethod embodiments, the cutting zone may be supplied with cooling water,which optionally may contain suspension siliceous sand, metal particlesor other abrasive particles. In some operations, the cooling water mayfurther include a surfactant to help increase the speed at which theblades penetrate the masonry materials, and it may reduce blade wear.

EXAMPLES

Examples are provided herein to illustrate the invention but are notintended to limit the scope of the invention.

Example 1

An as-mined block of Rosa Sardo granite is mounted in a swing-typemulti-blade frame system. The blades are pieces of hot-rolled steelhaving a length of more than 3.0 m, width of more than 3 mm, and heightbetween 50 and 200 mm. Each blade cutting edge has a plurality ofdiamond segments attached thereon by brazing.

After 3 hours of operation (and not cutting through the block), 30% ofthe diamond segments are torn off the blades.

Example 2

Example 1 is repeated with a similar size block of as-mined Rosa Sardogranite, with similar surface conditions. A mixture of mortar isprepared and applied onto the top of the block for a skim coatingsufficient to smooth out the surface irregularities for a uniform,smooth, and regular surface. The block is then mounted in themultiple-blade frame system of Example 1 with a new set of blades havingdiamond segments mounted thereon.

The blades cut through the block without losing any segments.

Example 3

An as-mined block of Rosa Sardo granite is mounted in a swing-typemulti-blade frame system. Alter mounting and tensioning the blade,expanding polymer foam ENERFOAM™ from Dow Chemical is sprayed betweenthe blades. The foam attaches to the blades, expands as it cures, andhardens into a stiff matrix.

As the cutting proceeds, the foam is worn away/pulverized by the sawingprocess. The resulting slabs have surface deviations of less than 1 mm.

Example 4

Example 3 is repeated with no spraying of polyurethane foam for asupport system.

The resulting slabs have surface deviations of between 1 and 1.5 mm.

While the invention has been described with reference to a preferredembodiment, those skilled in the art will understand that variouschanges may be made and equivalents may be substituted for elementsthereof without departing from the scope of the invention. It isintended that the invention not be limited to the particular embodimentdisclosed as the best mode for carrying out this invention, but that theinvention will include all embodiments falling within the scope of theappended claims.

All citations referred herein are expressly incorporated herein byreference.

The many features and advantages of the invention are apparent from thedetailed specification. Thus, the appended claims are intended to coverall such features and advantages of the invention which fall within thetrue spirits and scope of the invention. Further, since numerousmodifications and variations will readily occur to those skilled in theart, it is not desired to limit the invention to the exact constructionand operation illustrated and described herein. Accordingly allappropriate modifications and equivalents may be included within thescope of the invention.

1. A method for cutting a block of granite, marble, or like material,comprising: providing a frame saw comprising a plurality of spaced apartblades; positioning a support structure of a unifying materialperpendicularly across the blade of the frame saw, wherein the supportstructure is adhered to at least one of the blades for keeping theblades in fixed relative positions; subjecting the block to a sawingoperation using the frame saw; and at least substantially removing thesupport structure as the blades become submerged in the block.
 2. Themethod of claim 1, wherein the positioning comprises injecting anexpandable polymeric foam mixture in between the saw blades, whereby theexpansion of the foam keeps the blades in fixed relative positions. 3.The method of claim 2, wherein the foam comprises a polyurethane foam.4. The method of claim 1, wherein the blades are connected on both endsto a frame by tensioning rods.
 5. The method of claim 1, furthercomprising applying a compressive force perpendicularly to the parallelblades.
 6. The method of claim 1, wherein the blades comprisesuperabrasive-containing segments.
 7. The method of claim 1, wherein thesawing operation comprises using a slurry of steel shot and limedispersed in water.
 8. The method of claim 1, wherein the sawingoperation comprises using cooling water.
 9. A method for cutting a blockof granite, marble, or like material, comprising: applying a skim coatonto a surface of a block of material to form a substantially evensurface that is substantially devoid of high points, low points, anddrill holes: providing a frame saw system comprising a plurality ofspaced apart blades; positioning a support structure of a unifyingmaterial perpendicularly across the blades of the frame saw, wherein thesupport structure is bonded to at least one of the blades for keepingthe blades in fixed relative positions; subjecting the block having askim-coated even surface to a sawing operation using said frame sawsystem so as to divide the block into multiple slabs; and at leastsubstantially removing the support structure as the blades becomesubmerged in the block.
 10. The method of claim 9, wherein the skim coatcomprises cement and sand.
 11. A method for the manufacture of slabs bysawing comprising: providing a frame saw system for sawing a block ofmarble, granite, or masonry material, wherein the frame saw systemcomprises multiple blades connected to a frame; positioning a supportstructure of a unifying material perpendicularly across the blade of theframe saw, wherein the support structure is bonded to at least one ofthe blades for keeping the blades in fixed relative positions;subjecting the block to a sawing operation using the frame saw system soas to divide the block into multiple slabs; and at least substantiallyremoving the support structure as the blades become submerged in theblock.
 12. The method of claim 11, wherein the multiple manufacturedslabs have surface deviations of less than 1 mm.
 13. The method of claim11, further comprising applying a skim coat onto a surface of the blockof material before the sawing operation to form a substantially evensurface on the block.